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7550 Independence Drive Walton Hills, OH 44146-5541 Phone (440) 232-7900 Toll-free (800) 225-4379 Fax (440) 232-6294 Copyright 2009 NPK Construction Equipment, Inc. www.npkce.com H055-9640A.doc 03/09
SAFETY
Safety notices in NPK Instruction Manuals follow ISO and ANSI standards for safety warnings: DANGER (red) notices indicate an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING (orange) notices indicate a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION (yellow) notices indicate a potentially hazardous situation, which, if not avoided, may result in minor or moderate injury. ATTENTION (blue) notices in NPK Instruction Manuals are an NPK standard to alert the reader to situations which, if not avoided, could result in equipment damage.
ATTENTION
WARNING and BASIC OPERATING INSTRUCTIONS decals are included with each NPK hammer and installation kit. Decals must be installed in the cab, visible to the operator while operating the hammer. STAY CLEAR, PRESSURE VESSEL, GAS PRESSURE and TOOL SHARPENING decals are installed on all NPK hammer models. Keep them clean and visible. NPK will provide decals free of charge as needed.
1. Operator and Service personnel must read and understand the NPK INSTRUCTION MANUAL to prevent serious or fatal injury. 2. FLYING DEBRIS CAN CAUSE SERIOUS OR FATAL INJURY. Keep personnel and bystanders clear of hammer while in operation. Do not operate HAMMER without an impact resistant guard between the HAMMER and operator. NPK recommends LEXAN or equivalent material, or steel mesh. Some carrier manufacturers offer demolition guards for their machine. Check with the carrier manufacturer for availability. If not available, please call NPK. 3. Do not hardface or sharpen the tool point with a cutting torch. Excessive heat from torching or welding can cause embrittlement, breakage, and flying pieces. Resharpen by milling or grinding only, using sufficient coolant.
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SAFETY
4. Fully extend the tool while charging the HAMMER with nitrogen gas. Be sure that the retaining pin is installed. STAY CLEAR OF TOOL POINT WHILE CHARGING. 5. Do not disassemble a HAMMER before discharging the hammer gas pre-charge. 6. USE NITROGEN GAS ONLY! Store and handle nitrogen tanks per OSHA regulations. 7. Avoid high pressure fluids. Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or other lines. 8. Operate HAMMER from operators seat only. 9. Match HAMMER size to carrier according to NPK recommendations, see page 7. The carrier must be stable during hammer operation and during transport. 10. Do not make any alterations to the TOOL without authorization from NPK Engineering. 11. Use proper lifting equipment and tools when handling or servicing the HAMMER. 12. Wear ear protection if conditions warrant. Consult OSHA regulations. 13. Wear safety glasses at all times. Beware of flying debris. 14. If modifications are to be made, do not alter the HAMMER without authorization from NPK Engineering! 15. Use only genuine NPK replacement parts. NPK specifically disclaims any responsibility for any damage or injury that results from the use of any tool or parts not sold or approved by NPK. For further safety information, consult the AEM Hydraulic Mounted Breakers Safety Manual, AEM form MB-140 (NPK P/N H050-9600), which is furnished with every NPK hammer. To request an additional copy, please contact NPK at 800-225-4379 or Internet at www.npkce.com.
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CONTENTS
SAFETY ..................................................................................................................1 INTRODUCTION.....................................................................................................5 BASIC OPERATING INSTRUCTIONS....................................................................5 PRECAUTIONS FOR USING THE NPK HYDRAULIC HAMMER ..........................6 CARRIER MACHINE COMPATIBILITY ..................................................................7 HAMMER SPECIFICATIONS .................................................................................8 STRUCTURE ..........................................................................................................9 HAMMER SERIAL NUMBER LOCATION...............................................................11 PRINCIPLE OF OPERATION .................................................................................12 HYDRAULIC INSTALLATION .................................................................................13 MOUNTING INSTALLATION ..................................................................................17 ROUTINE INSPECTION AND MAINTENANCE......................................................18 WEEKLY INSPECTION ..........................................................................................19 CHANGING THE TOOL ..........................................................................................20 TROUBLESHOOTING ............................................................................................22 CHECKING THE HYDRAULIC PRESSURES ........................................................23 CHECKING THE HYDRAULIC FLOW TO THE HAMMER .....................................24 OIL LEAKAGE.........................................................................................................26 GAS LEAKAGE .......................................................................................................27 EXCESS OIL IN THE GAS HEAD INSPECTION PROCEDURE ............................28 NITROGEN GAS PRESSURE ................................................................................29 GAS CHARGING KIT..............................................................................................29 CHECKING THE GAS PRESSURE ........................................................................30 GAS CHARGING THE HAMMER ...........................................................................32 REMOVAL AND MOUNTING OF HYDRAULIC HAMMER .....................................33 TOOLS REQUIRED FOR DISASSEMBLY .............................................................34 NPK START-UP KIT ...............................................................................................35 NPK ASSEMBLY LUBRICANT ...............................................................................36 DISASSEMBLY PROCEDURE ...............................................................................37 DISCHARGING GAS PRESSURE..........................................................................38 DISASSEMBLING THE MAIN BODY......................................................................40 DISASSEMBLY OF MAIN VALVE ..........................................................................46 INSPECTION AND REPAIR AFTER DISASSEMBLY.............................................48 REPAIR SECTION INTRODUCTION......................................................................49 REPAIR TOOLS AND EQUIPMENT .......................................................................49 HAMMER SLEEVE AND PISTON RECONDITIONING TOOLS .............................50 MAIN BODY BORE REPAIR...................................................................................52 PISTON ACTIVE SEAL AREA REPAIR..................................................................62 PISTON TO SLEEVE RUNNING CLEARANCES ...................................................63 REPAIR THE STRIKING END OF PISTON ............................................................64 MAIN BODY SLEEVES...........................................................................................64 REPLACING THE SEALS.......................................................................................65 REASSEMBLY OF THE HAMMER .........................................................................67 STANDARD TOOLS ...............................................................................................83 ACCESSORY TOOLS.............................................................................................83
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CONTENTS
MAXIMUM TOOL TO TOOL BUSHING CLEARANCE ...........................................84 NPK HYDRAULIC HAMMER IMPACT BUSHINGS ................................................86 TOOL INSPECTION................................................................................................87 CHISEL TOOL RESHARPENING ...........................................................................88 STANDARD LENGTH FOR NPK TOOLS ...............................................................89 RETAINING PIN......................................................................................................90 LUBRICATION ........................................................................................................91 AUTOLUBE/UNDERWATER PORT IDENTIFICATION ..........................................94 TOOL BUSHING REPLACEMENT .........................................................................95 TOOL HOLDER BUSHING BORE REPAIR............................................................98 TOOL HOLDER ......................................................................................................101 REPLACEMENT OF TIE RODS .............................................................................102 MAXIMUM ELONGATION OF TIE RODS...............................................................104 TORQUE CHART....................................................................................................105 TORQUE VALUES FOR HAMMER FASTENERS ..................................................106 MOUNTING PLATE ................................................................................................107 WARRANTY REGISTRATION FOR NEW UNITS ..................................................108 WARRANTY STATEMENT .....................................................................................109 STORAGE OF HYDRAULIC HAMMER ..................................................................110 DECIMAL CONVERSION CHART ..........................................................................111 REBUILD SPECIFICATIONS CHECK SHEETS .....................................................112 NOTES....................................................................................................................119 SERVICE RECORD ................................................................................................119
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INTRODUCTION
NPK is a leading manufacturer of boom mounted HYDRAULIC HAMMERS, and has the most complete product line available anywhere. The success of NPK is due to our commitment to quality, dependability and long life. The HYDRAULIC HAMMER has many unique designed features and it is a company philosophy that the NPK HYDRAULIC HAMMER can be brought to "like new condition long after competitive products are scrapped. You can feel confident that you have purchased the best value available. This comprehensive instruction manual contains instructions for repairing and maintaining NPK HYDRAULIC HAMMERS. This manual includes helpful information for obtaining the full potential and efficiency from NPK HYDRAULIC HAMMERS. Please read this manual thoroughly to understand the NPK HAMMER and its operating principles before using it. For additional information or help with any problem encountered, please contact your NPK authorized dealer. Whenever repair or replacement of component parts is required, only NPK parts should be used. NPK is not responsible for failures resulting from substitution of parts not sold or approved by NPK.
If additional safety information is needed, consult the AEM Hydraulic Mounted Safety Manual. To request a free copy, please contact NPK at 800-225-4379 or e-mail us at www.npkce.com.
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HAMMER SPECIFICATIONS
HAMMER IMPACT MODEL ENERGY FREQUENCY CLASS ft lb bpm GH06 150 480 1200 WORKING WEIGHT lbs 500 235 550 270 750 450 800 525 1075 800 1250 2150 (Kg) (225) (107) (250) (125) (340) (205) (365) (240) (490) (365) (570) (980) MOUNTING STYLE TOOL WORKING LENGTH in (mm) in (mm) 1.7 (42) 12.2 (311) DIA
500 1200 550 1100 500 1300 500 1150 400 1050 500 800
Skid Steer Excavator Skid Steer Excavator Skid Steer Excavator Skid Steer Excavator Skid Steer Excavator Excavator Excavator
HAMMER MODEL OIL FLOW gpm 2.5 7 49 7 13 7 17 12 26 13 32 24 40 (L/min) (10 - 25) (15 - 35) (25 - 50) (25 - 65) (45 - 100) (50 - 120) (90 - 150)
HYDRAULIC OPERATING PRESSURE 1 psi (bar) 1650 (115) 1500 (105) 1750 (120) 2250 (160) 1900 (130) 2200 (150) 2400 (165)
CIRCUIT RELIEF minimum 2 psi (bar) 2150 (150) 2000 (140) 2250 (155) 2750 (190) 2400 (165) 2700 (185) 2900 (200)
GAS CHARGE PRESSURE 5 Cold 3 Hot 4 psi (bar) psi (bar) 350 (24) 405 (28) 350 (24) 405 (28) 350 (24) 405 (28) 350 (24) 405 (28) 350 (24) 405 (28) 375 (26) 435 (30) 390 (27) 450 (31)
*Specifications are subject to change without notice. NOTES: 1. Hydraulic operating pressure maximum is inlet pressure at the hammer with the oil at operating temperature and with the gas charge set at the hot operating pressure. See CHECKING THE HYDRAULIC PRESSURES section in this manual. 2. Circuit relief pressure is at least 500 psi (35 bar) above hammer operating pressure. 3. Cold gas charge is the initial set with the hammer at ambient temperature. 4. Hot gas charge is checked after 1 to 2 hours of running and with a system oil temperature of 140 to 180F (60 to 80C). This is the preferred check. 5. Pressures listed are maximum. Use tolerance of minus 25 psi (2 bar).
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STRUCTURE
STRUCTURAL DRAWING MODELS GH06 GH3
A B C D E F G J L M N P R U V W Y Z AA BB DD HH 30
MAIN BODY DRAIN PLUG TOOL HOLDER RETAINING PIN RETAINING RING UPPER TOOL BUSHING (GH3 ONLY) LOWER TOOL BUSHING SPACER SECTION GAS HEAD CHARGE VALVE PISTON MAIN BODY SLEEVE (B) TOP NUT WASHER BOTTOM NUT VALVE BODY VALVE BOTTOM CAP VALVE SPOOL PLUNGER BUSHING PLUNGER SWIVEL ELBOW TOOL GREASE FITTING
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STRUCTURE
STRUCTURAL DRAWING MODELS GH4 GH6
A B C D E F G J L M N O P R U V W Y Z AA BB DD HH 30
MAIN BODY DRAIN PLUG TOOL HOLDER RETAINING PIN RETAINING RING IMPACT BUSHING w/ UPPER TOOL BUSHING LOWER TOOL BUSHING SPACER SECTION GAS HEAD CHARGE VALVE PISTON MAIN BODY SLEEVE (A) MAIN BODY SLEEVE (B) TOP NUT WASHER BOTTOM NUT VALVE BODY VALVE BOTTOM CAP VALVE SPOOL PLUNGER BUSHING PLUNGER SWIVEL ELBOW TOOL GREASE FITTING - 10 -
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PRINCIPLE OF OPERATION
OPEN VALVE
(1) UPSTROKE (2) VALVE SHIFT (3) POWER STROKE (4) IMPACT
N Z BB HH 5 6
33 34 35 36 37
NITROGEN GAS CHAMBER ABOVE PISTON UPPER CHAMBER OF PISTON LOWER CHAMBER OF PISTON CHAMBER OF VALVE SPOOL NITROGEN GAS
(1)
UPSTROKE OF PISTON Hydraulic oil supplied by the carrier machine hydraulic pump enters the NPK HAMMER "IN" port (6) and is directed through port (h1) to the top of the valve plunger, forcing the main valve spool (Z) to the down position. Oil flows through the main valve spool (Z) to the lower chamber of the piston (35). The oil pressure acts on the piston (N), raising the piston up, compressing the nitrogen gas (37). Oil in the upper chamber of the piston (34) is forced out the return line through port (h2). (2) VALVE SHIFT As the piston (N) rises, lower chamber (35) is opened to passage (h3) and oil flows into the chamber (36) of the main valve spool (Z). Since the area acting on the main valve spool (Z) in chamber (36) is greater than the area of the plunger (BB), the main valve spool (Z) shifts up. (3) POWER STROKE With the main valve spool (Z) in the up position, chamber (35) is closed off from the "IN" port (6) and opened to chamber (34) and the return line via passages (h4), (h5), and (h2). The piston (N) is driven downwards by the compressed nitrogen gas (37) as the oil in lower chamber (35) re-circulates to upper chamber (34). When the piston (N) opens passage (h3) to upper chamber (34), the oil in main valve spool chamber (36) is switched to low pressure and the main valve spool (Z) shifts down. (4) IMPACT The piston (N) impacts the tool (HH) and the main valve spool (Z) shifts to the down position. High pressure oil is directed to the lower chamber of the piston (35) for the start of another cycle.
AUTOMATIC ENERGY RECYCLING: Extremely hard material will impart greater rebound energy to the piston (N) after it strikes the tool (HH). This will assist the incoming oil in raising the piston (N) against the gas pressure in chamber (33). This reduces upstroke time and therefore increases hammer frequency (beats per minute). The impact force of the hammer remains the same on each impact.
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HYDRAULIC INSTALLATION
NPK INSTALLATION KITS are available for virtually all compatible backhoe loaders, excavators, and skid steers. Complete parts and instructions for the hydraulic installation of the NPK HYDRAULIC HAMMER including valving and/or controls, hoses and fittings, boom and stick tubing, and clamps are provided.
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HYDRAULIC INSTALLATION
PREVENTION OF CONTAMINATION
1. A hydraulic hammer is harder on oil than using a bucket, so the oil is apt to deteriorate and breakdown sooner. Neglect of the oil system can not only damage the hydraulic hammer but also cause problems in the carrier which could result in damaged components. Care should be taken to check for contamination of the oil and to change it if it is found contaminated. Oil sampling at regular intervals is highly recommended. When the hydraulic oil shows low viscosity and bubbles, this indicates that the oil is deteriorated. If the oil is dark brown and gives off an offensive odor, it is severely deteriorated. Change the oil immediately! When the oil is clouded, or the oil filter often becomes clogged, it indicates that the oil is contaminated. Change the oil immediately! To change the contaminated hydraulic oil, drain the hydraulic system completely and clean components. Do not mix new oil with the old. 2. Do not allow any contamination to mix with the oil. Take special care in preventing contamination from entering the hydraulic system through the hose or tube connection when changing the hydraulic hammer with the bucket. 3. Low oil level will cause heat build-up, resulting in deterioration of the oil. Also, it may cause cavitation due to air mixing with the oil, leading to a damaged hydraulic hammer and carrier components. Keep the oil at the proper level at all times. 4. Do not use the hydraulic hammer at an operating temperature higher than 180F (80C). The proper operating oil temperature range is between 120F (50C) and 180F (80C). Since contaminated cooler fins causes reduced efficiency of the cooler, keep the cooler fins clean at all times. Check the hydraulic oil cooling system to be sure it is working effectively. The use of a heat gun is the best way to evaluate if the cooler is working properly. 5. Water in the hydraulic oil will lead to damage of the hydraulic hammer and carrier. Drain off water and foreign matter from the hydraulic tank at specified intervals. When out of service, the hydraulic hammer should be stored indoors.
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HYDRAULIC INSTALLATION
HYDRAULIC QUICK DISCONNECTS NPK recommends against the use of non-NPK quick disconnects on hydraulic circuits operating NPK Products.
1. The hydraulic pulsations caused by hydraulic hammer operating can cause internal pieces of non-NPK quick disconnect (32) to disintegrate. These pieces would migrate into the hammer, causing damage. 2. If quick disconnects are used when the hammer is removed from the excavator, the quick disconnects should be capped to keep them clean. If this is not done, contamination in the disconnect will be flushed into the hammer when re-connected. This, again, can cause damage. 3. Most quick disconnects create a restriction in the circuit. NPK Hammers are not back pressure sensitive, but restrictions cause unnecessary heating of the oil. Also, the pressure required to operate the hammer, plus the restriction in the disconnects may push an older, low pressure, carrier machine to the limit of its hydraulic system. This would interfere with proper hammer operation. However, the NPK approved quick disconnects (DX) are properly sized so that the hammer operation is not affected. APPROVED CONNECTION (39) NOT RECOMMENDED CONNECTION Non-NPK Quick Disconnects (32)
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HYDRAULIC INSTALLATION
HYDRAULIC QUICK DISCONNECTS
If hydraulic quick disconnects (32) are used with the NPK Hammer, it is recommended that the following precautions be followed. 1. Periodic inspection of both male and female ends is recommended to ensure the couplers are in good working condition. Failure to inspect couplers may result in pieces from a damaged or failed coupler to be injected into the hammer or parts of the coupler returned to the machine. 2. Check for dirt, dust, and debris on both couplers (32) before coupling. 3. Be sure that the couplers are completely seated together (38). 4. When replacing couplers, be sure that couplers are replaced as a set, male and female. Do not use one new end and one used end.
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MOUNTING INSTALLATION
NPK Mounting Installation Kits include the parts required to adapt the NPK HYDRAULIC HAMMER to the carrier. NPK mounting kits include the hammer mounting bracket, flow control valve (if required), and hoses to connect to the carrier hydraulic system.
m1 m2 m3 m4 m7 m8 m9
Stick Pin (If Required) Link Pin (If Required) (Whip) Pressure Hose (Whip) Return Hose Top Bracket Hammer Bolt Package Klik Pin
*TORQUES OF ALL BOLTS SHOWN ARE WITH THREADS BEING LUBRICATED WITH ANTI-SEIZE COMPOUND. HAMMER BRACKET BOLT TORQUE DIA ft/lb (Nm) 1 500 (678) 1 500 (678) 1 500 (678) 1 500 (678) 1-1/4 1000 (1356) 1-1/2 1250 (1695) 1-1/2 1250 (1695) ADAPTER BRACKET BOLT TORQUE DIA ft/lb (Nm) 5/8 165 (225) 5/8 165 (225) 5/8 165 (225) 5/8 165 (225) 5/8 165 (225) 5/8 165 (225) 1 550 (745)
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USE A GOOD QUALITY, HIGH TEMPERATURE EP#2 GREASE CONTAINING ANTIWEAR ADDITIVES. NPK recommends a Lithium Base, Moly (Molybdenum Disulfide) or other surface protecting additives, EP (Extreme Pressure), NLGI #2 Grease. A high drop point (350 to 400) grease is desirable. If machine is equipped with an AUTOLUBE System, check grease reservoir daily.
3. TOOL and TOOL BUSHING WEAR Check the tool and tool bushings for damage, wear or deformation on a regular weekly basis. Replace the tool and/or bushings when wear exceeds the maximum clearance limit. See MAXIMUM TOOL TO TOOL BUSHING CLEARANCE, see pages 84 and 85.
Do not hardface or sharpen the tool point with a cutting torch. Excessive heat from torching or welding causes embrittlement, breakage, and flying pieces. Resharpen only with a lathe or milling machine using sufficient cooling. Please consult your authorized NPK Dealer or NPK Service Department for additional information.
WEEKLY INSPECTION
1. TIE RODS AND FASTENERS
Inspect tie rod assemblies for cracked or missing lock plates and lock rings. If lock plates are missing, consult the NPK Service Department at 800-225-4379. Inspect all fasteners and retighten as necessary, see pages 105 and 106.
2. WELDS
Check for cracks and repair as necessary, see page 107. Consult your authorized NPK Dealer or NPK Service Department for additional information.
4. DEMOLITION TOOL
Remove the demolition tool and inspect for peening caused by excessive blank hammering. If necessary, grind edges smooth as shown in TOOL INSPECTION, see page 87.
5. GAS CHARGE
Check and adjust, if required, see pages 29 through 32.
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Figure 1
Figure 2
Figure 3
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Figure 4
Figure 5
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TROUBLESHOOTING
UNDERSTAND THE BASICS:
1. The NPK HYDRAULIC HAMMER hydraulic operating pressure is determined by the nitrogen gas pre-charge pressure in the hammer, not the relief valve setting of the carrier. NPK Hydraulic Hammers are self-regulating for hydraulic pressure. 2. The NPK HYDRAULIC HAMMER energy per blow is determined by the nitrogen gas pre-charge pressure, not the pump volume. Impact energy is proportional to gas pressure. 3. The NPK HYDRAULIC HAMMER frequency (blows per minute) is determined by oil flow to the hammer. Frequency is proportional to oil volume (gallons per minute or liters per minute). The hammer circuit must be set to provide the correct flow to the hammer.
TROUBLESHOOTING CHART
PROBLEM
Loss of impact power. Loss of frequency. (hammer slows down)
CAUSE
Low gas pressure. Gas pressure too high. Shut-off valve partially closed. Relief valve set too low (must be 400 to 500 psi over hammer pressure). Hyd. temperature too high (over 180F). Hydraulic pump volume too low. Oil level of carrier too low. Defective pump or control valve. Shut-off valve closed. Hoses reversed. Return line blocked. Oil level of carrier too low. Gas pressure too high. Zero gas pressure. Hammer main valve malfunctioning. Piston not cycling.
CHECK
Gas pressure Gas pressure Valve position HYD Pressure
REMEDY
Recharge gas. Reduce gas pressure. Open valve. Adjust or replace.
Oil Temperature Oil Flow Oil Level HYD Pressure HYD Pressure HYD Pressure HYD Pressure Oil Level Gas Pressure Gas Pressure HYD Pressure HYD Pressure
Reduce throttle, clean or add oil cooler. Increase circuit flow. Add hydraulic oil. Repair or replace. Open valve. Pressure is on left. Return is on right. Eliminate obstruction. Add hydraulic oil. Reduce gas pressure. Check for leak and repair. Disassemble and inspect valve components. Disassemble hammer and inspect piston.
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1. Determine Return Line Pressure Turn both shut-off valves (k4) to the on position and operate the hammer. The return line pressure should not exceed 300 psi (21 bar). 2. Determine System Relief Valve Pressure Turn the pressure line shut-off valve (k4) to the off position. Energize the hammer control circuit and note the Stay clear of hammer when checking line pressures. relief valve setting. The relief valve is only used for ultimate safety, when the hammer is removed or the shut-off valve is closed, not to set the hammer operating pressure. Therefore, to prevent overheating, loss of flow and reduced hammer frequency, the relief pressure should be set a minimum of 500 psi (35 bar) above the hammer operating pressure. 3. Determine Hammer Operating Pressure Open both shut-off valves. Operate the hammer and note the operating pressure. The operating pressure of the NPK HYDRAULIC HAMMER is self-regulating, determined by the gas pressure. If the operating pressure is low, check the gas pressure, see pages 29 through 30. MODEL GH06 GH07 GH1 GH2/GHS2 GH3 GH4 GH6 HYDRAULIC OPERATING PRESSURE psi (bar) 1650 (115) 1500 (105) 1750 (120) 2250 (160) 1900 (130) 2200 (150) 2400 (165)
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CIRCUIT RELIEF MINIMUM psi (bar) 2150 (150) 2000 (140) 2250 (155) 2750 (190) 2400 (165) 2700 (185) 2900 (200)
Generally, the pressure line is on the left and the return is on the right.
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OIL LEAKAGE
Exceeding 180F (80C) hydraulic operating temperature reduces seal life. A small amount of oil leakage between the tool and tool bushing at location (pr2) is considered normal. If oil leak is significant, locate the point of origin. Oil running down the tool may be coming from a loose hose. It is normal for a new seal to leak slightly until the seal seats with usage.
CAUSE
Seal in main body sleeve A. Seal in main body sleeve B.
REMEDY
Disassemble hammer and replace seals. Disassemble hammer and replace seals.
O-ring between valve and body. Loose bolts. O-ring under valve cap. Loose bolts. O-ring under valve cap. Loose bolts. O-ring under swivel. Loose or damaged hose fitting. Seal in swivel.
Replace. Use thread adhesive, tighten. Replace. Tighten. Replace. Tighten. Replace. Tighten or replace. Replace.
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GAS LEAKAGE
(If the gas pressure drops over 25 psi (2 bar) per day).
Exceeding 180F (80C) hydraulic operating temperature reduces seal life.
TO LOCATE GAS LEAK, APPLY SOAPY WATER (t23) AT THE POINTS INDICATED. PROBLEM
(pr1) (pr9) Leakage through vent plug. Leakage from top of charge valve. Leakage between charge valve and head. Leakage between head and main body.
CAUSE
Seal in main body sleeve A. O-ring in check valve. Damaged check valve in charge valve. O-ring in charge valve. Loose charge valve. O-ring in head.
REMEDY
Disassemble hammer and replace seals. Replace. Replace. Replace. Use thread adhesive, tighten. Disassemble hammer and replace seals.
(pr10) (pr11)
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MODEL
PRECHARGE Cold Cold psi bar 350 24 350 24 350 24 350 24 350 24 375 26 390 27
AT LOAD Cold Cold psi bar 385 26.5 385 26.5 400 27.5 400 27.5 400 27.5 425 29.5 440 30.5
PRE-CHARGE Hot Hot psi bar 405 28 405 28 405 28 405 28 405 28 435 30 450 31
AT LOAD Hot Hot psi bar 450 31 450 31 465 32 465 32 465 32 495 34 505 35
1. Cold gas charge is the initial set with the hammer at ambient temperature. 2. Hot gas charge is checked after 1 to 2 hours of running and with a system oil temperature of 140 to 180F (60 to 80C). This is the preferred check.
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CHARGE ADAPTER (PART NO. 30604040) PLUG (PART NO. 30102050) HOSE (PART NO. 20118010) CHARGING KIT BOX (PART NO. 35001030) CAP (PART NO. 30100500) OPTIONAL REGULATOR VALVE (PART NO. 21101050)
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PROCEDURE
1. The gas pre-charge is measured with no preload on the tool. Remove the tool or position the hammer with the tool fully extended. THE HAMMER MUST NOT BE RESTING ON THE POINT.
4. MODELS GH06, GH07, GH1, GH2/GHS2 Remove plug (g12). Install adapter (g13) part no. 30604100 into the female port on the gas head. Install NPK charging adapter (g1).
4. MODELS GH3, GH4 and GH6 Only Install the NPK charging adapter (g1) on the hammer charge valve (M).
Remove the valve cap only, not the charge valve assembly!
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6. Turn the T-handle (g2) clockwise. As the T-handle is screwed in, a resistance is encountered. By turning the T-handle further, the nitrogen gas pressure will be indicated on the pressure gauge (g8). Stop turning the T-handle when the gauge reads pressure. Do not over tighten. 7. Compare the gauge pressure with the NITROGEN GAS PRESSURE CHART, see page 29. If the gas pressure is 25 psi (2 bar) or more below specification, proceed to NITROGEN GAS CHARGING PROCEDURE. If the pressure is correct, go to the next step. 8. Turn the T-handle (g2) counterclockwise until it stops as in step 3. 9. Slowly loosen the charge adapter cap to relieve the nitrogen gas pressure trapped in the charge valve. 10. Remove the charge adapter from the hammer charge valve. 11. Remove NPK adapter part no. 30604100. 12. Reinstall existing plug.
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PROCEDURE
1. Carry out steps 1 thru 4 of CHECKING THE GAS PRESSURE, see page 30. 2. Remove the cap from the charge adapter. Remove the valve cap only, not the charge valve assembly!
4. Connect a hose from the 6. Turn the handle (g7) on the pressure regulator on the tank regulator nitrogen tank (g9) to the counterclockwise to fully charge adapter (g1). close. 5. Turn the T-handle (g2) on 7. Open the valve (g10) on the charge adapter (g1) the nitrogen tank by turning clockwise. the T-handle counterclockwise.
8. Slowly adjust the regulator on the nitrogen tank to the correct pressure by turning clockwise. See NITROGEN GAS PRESSURE CHART or decal (g11) on hammer. 9. Charge nitrogen gas until the pressure gauge (g8) on the charge adapter (g1) is at the correct setting, then turn the Thandle (g2) counterclockwise all the way out. 10. Close the nitrogen tank valve and then remove the hose from the charge adapter (g1). Nitrogen gas may be trapped in the hose. Loosen fittings slowly to release pressure. 11. Remove the charge adapter (g1) from the hammer charge valve. 12. Reinstall existing plug.
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DISASSEMBLY PROCEDURE
A sturdy work bench is recommended for disassembly and assembly of an NPK HYDRAULIC HAMMER.
REMOVE THE HAMMER FROM THE BRACKET 1. Place the hammer on blocks (t20). Make sure the hammer is stable. NOTE: DO NOT REMOVE TOOL FROM HAMMER AT THIS TIME! 2. Remove the bracket bolts (m11), nuts (m12), and washers (m13). 3. Remove hydraulic hoses. Plug hose ends and hammer ports to prevent contamination from entering. 4. Lift the hammer (KK) from the bracket (LL). Using a hoist, attach a chain (t4) or strap (t27) to the hammer and lift it out of the bracket (LL).
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2. Turn the NPK charging adapter Thandle (g2) counterclockwise until it stops.
3. The NPK GH06, GH07, GH1 and GH2/GHS2 hydraulic hammers have a gas charge fitting in the gas head that is different from all other NPK hydraulic hammers. After removing the existing plug (g12), the adapter (g13), part no. 30604100 is threaded onto the existing GH06, GH07, GH1 and GH2/GHS2 gas charge fitting. This adapter is included in the gas charge kit that is provided with the hammer and allows use of the standard NPK gas charge valve (g1), part no. 30604040.
4. Install the NPK charging adapter (g1) on the hammer charge valve (M).
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6. Turn the T-handle (g2) clockwise. As the Thandle is screwed in, a resistance is encountered. By turning the T-handle (g2) further, the nitrogen gas pressure will be indicated on the pressure gauge (g8). Stop turning the Thandle when the gauge reads pressure. Do not over tighten.
7. Loosen the charge adapter cap (g6) VERY SLOWLY. The gas pressure will gradually decrease to zero; then REMOVE THE CAP. 8. Remove the charge adapter (g1) from the hammer. 9. Remove NPK adapter part no. 30604100. 10. Install existing plug.
- 39 -
- 40 -
ATTENTION
When the gas head is removed, hydraulic oil will flow out of the body bore. Therefore, have oil pans ready.
The tool holder must be kept level and square to the main body.
- 41 -
Loosen the tie rods (Q) with a wrench (t6) by hand. If a tie rod (Q) should fail to turn, rap the bottom nut (V) with a hammer (t29). If the tie rods (Q) are still tight, reposition the tool holder to remove the bind on the tie rods (Q). Loosen all four of the tie rods (Q) before removing any of them.
7. Hoist the tool holder by a crane to remove it from the main body.
8. Remove the spacer section (J). Hoist the spacer section (J) by a sling (t27) to remove it from the main body.
- 42 -
a. Bump a nylon bar (t3) on the end of the piston at the tool holder end (1) and drive the sleeves (O,P) and piston out.
Hydraulic oil comes out of the body each time the sleeves move. Direct the port of the swivel adapter downward.
b. To prevent damage to the body bore, support A sleeve (O) with a sling (t27) as it comes out. c. Do not use a steel bar to
Use a nylon strap (t27) to support the piston and sleeves as they are removed from the body bore.
- 43 -
String chain through tie rod holes and wrap around back of portable power unit, NPK part no. T000-1031. e. Push piston and sleeves from the tool end of body and out gas end (2).
- 44 -
f. Keep the sleeves (O,P) level by adjusting tension on the sling (t27).
When the sleeves come out of the body, hydraulic oil flows out. Have an oil pan ready to catch it.
g. Lay the piston (N), A sleeve (O) and B sleeve (P) assembly on a piece of cardboard (t30) on a table (t31).
h. Separate A sleeve (O) from the piston (N) by tapping the sleeve with a dead blow hammer (t2). When removing the sleeves and piston as a unit, the point of balance will be on the B sleeve (P) near where the A sleeve (O) joins it.
ATTENTION
Do not use steel bar to drive apart sleeves!
11. Remove the piston (N) from the B sleeve (P). Separate the piston (N) from the B sleeve (P) by rapping the striking end of the piston (N) with a dead blow hammer (t2). The piston (N) will slide out of the B sleeve (P).
- 45 -
1. Remove the bottom cap (Y) from the main body (W). a. Remove the cap screws from the bottom cap (Y) with a hex wrench (t25) and extension bar (t32).
b. Remove the bottom cap (Y). Use a screwdriver (t22) (or pry bar) to remove cap (Y).
2. Remove the plunger bushing (AA). Do not force the bottom cap (Y) when removing it, otherwise, the valve body (W) will be damaged, causing oil leaks. a. Remove cap screws from the plunger bushing (AA) with a hex wrench.
b. Use a nylon bar (t3) in the main valve body (W) at the bottom cap end (3) and drive the plunger bushing (AA), and the valve spool (Z) out of the case with a hammer.
- 46 -
c. Remove the valve spool (Z) from the valve body (W).
e. Remove the swivel adapters. 1. Remove the snap ring (AJ) with snap ring pliers, then remove the washer (AH). Pull the swivel elbows (DD) off of the swivel flanges (EE). 2. Remove the cap screws (OO) from the swivel flanges (EE) and then remove the swivel flanges (EE).
f. Remove the main valve body. It is rarely necessary to remove the valve body from the main body. If disassembly is needed for any reason, proceed as follows. Attach a 6 ft. (2 meter) long extension pipe to the hex wrench and with it loosen each bolt. There is thread adhesive on each bolt. Use heat on the head of any bolt that is found difficult to remove.
ATTENTION
DO NOT HEAT EXCESSIVELY!! DO NOT HEAT THE VALVE CASE OR MAIN BODY!!
- 47 -
b. Worn or deformed backup ring. 2. Hammer Internals a. Piston Check the sliding areas for damage and the striking area for damage or deformation. Repair or replace, if necessary. b. A and B sleeves Check the inner surface for damage and repair or replace if necessary. Complete hammer check sheets and fax to NPK for advice on reuse of main components. c. Valve spool Check the sliding area for damage, deformation, or wear and repair or replace, if necessary. d. Valve case Check the inner surface for damage or wear and repair or replace, if necessary. e. Swivel adapter Check the seal contact area for damage or wear and repair or replace, if necessary.
c. Worn or deteriorated u-cup seal. 3. Tool and Tool Bushing Wear See pages 84 and 85 of this manual, Maximum Tool to Tool Bushing Clearance. 4. General a. Check for damage, breakage, deformation, wear and rust and repair or replace, if necessary. b. Check for contamination and remove, if any.
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Air or electric handheld grinder (NPK brand air grinder is recommended, p/n NHG-65LD). NPK Assembly Lube, p/n H010-5010. Polishing wheel (available from NPK, p/n 25026030). Oil stone Emery cloth (200 grit) Cleaning solvent
- 49 -
t8 t9 t10
DESCRIPTION LONG SHAFT STRAIGHT GRINDER POLISHING WHEEL used for cleaning seal grooves in sleeves. (Green) POLISHING WHEEL used for final polishing of piston, sleeves and main body bore. (Gray) GRINDING WHEEL used to grind weld. (Red) CUT-OFF WHEEL used to clean and repair pressure balancing grooves in the sleeve land area.
- 50 -
(t7) 25026050 POLISHING WHEEL (GREEN) USE THIS WHEEL FOR CLEANING OUT SEAL GROOVES IN NPK A AND B SLEEVES.
(t8) 25026030 FINISH POLISHING WHEEL (GRAY) USE THIS WHEEL FOR FINAL POLISHING OF PISTON, MAIN BODY AND GLAND RING AREA OF NPK A AND B SLEEVES.
(t9) 25026020 GRINDING STONE (RED) USE THIS STONE FOR GRINDING WELD IN HAMMER MAIN BODY.
(t10) T050-7500 CUT-OFF WHEEL USE CUT-OFF WHEEL TO CLEAN AND REPAIR PRESSURE BALANCING GROOVES IN NPK A AND B SLEEVES.
NOTE:
WHEN RECONDITIONING PARTS, IF YOU ARE UNSURE OF THE PROPER PROCEDURES, CONSULT THE NPK SERVICE MANUAL OR CONTACT THE NPK SERVICE DEPARTMENT AT 1-800-225-4379.
- 51 -
2. If no damage is noted in the o-ring areas, use a ball hone to break the glaze in the bore of the body. DO NOT USE A FIXED HONE! USE ONLY 6 STROKES OF A BALL HONE! REMEMBER: ONCE THE SLEEVES ARE INSTALLED, THE O-RINGS BECOME STATIONARY AND DO NOT MOVE OUT OF THE AREA THEY REST IN. 3. If a scratch runs across several o-ring areas: a. Polish o-ring rest areas to blend with surrounding area. b. If scratches are not removed by use of a ball hone, see Repairing Body Bore By Grinding and Polishing. 4. If score in o-ring area is too deep to polish and blend, the body may be welded in these areas and hand ground / polished, see Repairing Body Bore By Welding and Polishing.
- 52 -
1. Take an NPK polishing wheel, part no. 25026030 (gray) (t8) and taper (45) each side so that the wheel is V shaped. This can be done by holding the wheel against the edge of a metal surface for several seconds.
2. Using a rocking motion, polish the erosion groove until the rough edges are removed. This must be done so that the o-rings on the O.D. of the sleeves will not be damaged during installation. 3. Clean bore using a ball hone making no more than 6 strokes. DO NOT HONE USING A FIXED HONE! 4. After polishing, clean main body bore to remove all grinding debris.
NOTE: WHEN REASSEMBLING THE HAMMER, USE A LIBERAL AMOUNT OF GREASE IN THE POLISHED AREA.
- 53 -
The areas (9) of the bore that are sealed by o-rings can be located by the discoloration. To prevent oil and/or gas leakage, special care must be taken to obtain a smooth finish with no pinholes, undercut, or uneven finish in the o-ring areas. If you are unsure of where the o-ring areas are located, measure these areas on the outside of the sleeves and mark in the body using a permanent marker to show o-ring areas. If a deep score (11) or scratch (deeper than .006 inch (.15 mm), that cannot be repaired by grinding is found in the body bore, repair this by welding, see Repairing Body Bore By Welding and Polishing.
- 54 -
GRIND ROUGH EDGES OF THE ENTIRE LENGTH OF THE SCRATCH. (t8) POLISHING WHEEL (GRAY)
POLISH SCRATCHES IN THE O-RING AREAS (9) TO A SMOOTH SURFACE. BLEND THIS AREA TO THE SURROUNDING SURFACE. DO NOT OVER POLISH!
CHECK BORE DIMENSION WITH A BORE GAUGE (t11), COMPARE WITH SPECIFICATIONS SHOWN IN CHART ON PAGE 61.
- 55 -
- 56 -
REPAIR PROCEDURE:
1. Carefully grind the score (11) until it is flush with the surface, especially in the o-ring rest areas, as in area (10).
- 57 -
3. After welding, grind weld until almost flush with the bore. Change to a fine polishing stone and finish until flush or just below flush. The seal areas of the o-rings cannot tolerate undercut and/or rough surfaces.
ATTENTION
DO NOT HONE BODY WITH A FIXED HONE! USE A BALL HONE ONLY MAKING NO MORE THAN 6 PASSES.
4. After polishing area, remove all o-rings and backup rings from B sleeve. Push B sleeve through body to check for high spots. If sleeve will not go through body, identify high spots and continue polishing.
- 58 -
- 59 -
3. Clean bore of the body. Check dimensions of I.D. Compare to the chart on page 61. If dimensions are within usable limits, reassemble the hammer. If dimensions are outside the allowable range, contact NPK for assistance.
- 60 -
MODEL
PART NUMBER
N/A
GH06
GH07
2.965
75.30
N/A
N/A
GH1
3.555
90.30
T050-7600
GH2/GHS2
3.949
100.30
T050-7600
GH3
4.539
115.30
4-1/2
T050-7605
GH4
4.933
125.30
T050-7610
GH6
5.917
150.30
T050-7610
NOTE: *Body bore maximum I.D. is not to exceed .010 (.25 mm) above standard (new) dimension. If bore is at or above this dimension, call the NPK Service Department at 1-800-225-4379.
- 61 -
MODEL GH06 GH07 GH1 GH2/GHS2 GH3 GH4 GH6 in 1.14 1.18 1.61 1.61 2.17 2.2 2.56
d11 in 4.17 4.17 4.65 4.65 5.08 5.98 6.38 mm 106 106 118 118 129 152 162
- 62 -
If the measurements are smaller than the values shown in the chart below, the piston and sleeves are reusable. If any of the measurements exceed the values shown, call the NPK Service Department at 800-225-4379, for recommendations on parts replacement.
MODEL
GH06 GH07 GH1 GH2/GHS2 GH3 GH4 GH6
in
.010 .010 .010 .010 .010 .010 .010
d10 mm
.25 .25 .25 .25 .25 .25 .25
d11 in
.010 .010 .010 .010 .010 .010 .010
d12 mm
.25 .25 .25 .25 .25 .25 .25
in
.004 .004 .004 .004 .004 .004 .006
mm
.11 .11 .11 .11 .11 .11 .15
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NEW d13 MODEL GH06 GH07 GH1 GH2/GHS2 GH3 GH4 GH6 inch 13 13.10 15.60 16 17.90 21.40 23.50 mm 329 332 396 406 454 544 598
MINIMUM d14 inch 12.70 12.80 15.30 15.70 17.50 21.00 23.10 mm 323 326 388 398 444 534 588
NOTE: GHS2 has extra machining for the anti-blank firing feature. GH4 GH6
O. P. AP. PP. QQ. RR. SS. 1. 2. A SLEEVE B SLEEVE WEAR BAND U-CUP SEAL DIRT SEAL O-RING BACKUP RING TOOL END GAS END
(DEFECTIVE SEALS) ALL DEFECTIVE SEALS SHOULD BE REPLACED WITH NEW ONES. 41. O-RINGS DEFORMED, WORN, WARPED, DAMAGED OR DETERIORATED BACKUP RINGS WORN OR DEFORMED U-CUP SEALS WORN OR DETERIORATED
42. 43.
Some minor leakage may be found for a while after new oil seals are installed, the oil leak will stop when the seal seats itself in use.
- 65 -
HOW TO HOLD THE U-CUP SEAL b. Installation should be performed quickly, taking care to observe the correct direction. Taking too much time might let the u-cup take a set, which could cause leaks. c. Care should be exercised as not to damage the lip when installing the u-cup seal. Installation of damaged u-cup seals will cause oil leaks. d. After installing u-cups in the sleeve, coat them with grease to assist with piston installation. e. GH06 GH3 only install seal (PP) from gas end (2) of hammer body. 2. INSTALL THE O-RINGS AND BACK UP RINGS a. Install the o-rings. b. Curl the back up rings, as shown below, and install. c. After installing, coat the o-rings and back up rings with grease.
c. Push B sleeve (P) into the main body (A) bore from the gas head end with pressure port (6) and tank port (5) facing upward. Insert the sleeve using a sling (t27) until the seals reach the body bore. Bump the sleeve into the bore until it is almost flush with the end of the body. Use a dead blow hammer (t2) or a nylon bar. Keep the sleeve level as it enters the bore.
NOTE: USE AN OLD LOCK PLATE (S) TO PREVENT THE B SLEEVE (P) FROM TRAVELING INTO THE MAIN BODY (A) BORE.
- 67 -
ATTENTION
Care should be exercised so as not to damage B sleeve when moving the piston up and down.
5. Install the dowel pins (K). Apply a small amount of grease on the two dowel pins and install them in B sleeve (P). The grease holds the pins in place.
6. Install A sleeve (O). a. Install the seals in A sleeve (O). b. Apply hydraulic oil on the inner surface of the sleeve. c. Align the dowel pin holes with the dowel pins in B sleeve (P) and insert A sleeve (O). d. Push A sleeve (O) over the piston until it contacts B sleeve (P) and traps the dowels.
ATTENTION
Be sure that the A and B sleeves have no gap between them before pushing them into the main body.
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1. Pin chain (t4) to diagonally opposite tie rod holes (44) in main body (A) at tool end (1).
String chain (t4) through tie rod holes and wrap around back of portable power RAM cylinder (t5).
Support the end of the B sleeve (P) with a sling (t27) and insert into the gas end of the main body (A). Bump with a dead blow hammer (t2). Align ports with main body (A).
Push B sleeve into body from gas end of body (1) with portable power unit (t33). Push B sleeve (P) using a push plate (t26) almost flush with gas end of body (1). Watch o-rings and back up rings as they enter bore. If seal starts to extrude, stop and push seal back into groove.
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3. Using a lock plate as a stop to keep B sleeve (P) from going any further at this point. 4. Install the piston (N). 5. Install A sleeve (O).
Carefully insert the piston (N) into B sleeve from the gas end of the main body.
Apply lubricating oil or NPK assembly lube to inside and outside diameters of A sleeve (O). Align dowel pin holes and install A sleeve (O) onto piston (N), flush with B sleeve (P).
a.
- 70 -
6. Use portable power unit (t33) to push A sleeve (O), piston, and B sleeve into position from the gas end (1). Use the dimensions in the chart on page 72 to locate final position. Take care to watch o-rings and back up rings on the sleeves as they enter the bore. 7. Make sure B sleeve is in proper position. See chart below for installation dimensions of correctly installed sleeves.
A. O. P. 5. 6. MAIN BODY MAIN BODY A SLEEVE MAIN BODY B SLEEVE OUT PORT IN PORT
- 71 -
Push the piston and sleeves into the body bore until the ports in B sleeve (P) line up with the ports in the body. Check dimension (d1) to be sure sleeves are in their correct location. Check d2. If d2 is less than the value shown, then A sleeve (O) is not fully engaged into B sleeve (P). Hold B sleeve (P) and try and bump A sleeve (O) into position. If this doesnt work, the sleeves must be bumped back out of the bore until A sleeve (O) comes clear. The problem can then be identified and corrected. d2 MODEL GH06 GH07 GH1 GH2/GHS2 GH3 GH4 GH6 inch N/A N/A N/A N/A N/A 1.25 1.62 mm N/A N/A N/A N/A N/A 31 41 inch .69 .69 .75 .78 .94 1.12 1.25 d1 mm 18 18 19 20 24 29 32
- 72 -
9. Install the o-ring (RR) into the counter bores of the grease passage of the spacer section (J). Seal the o-ring (RR) into place with a bead of RTV Silicone.
10. Install the spacer section (J). Align the dowel pins on the B sleeve with dowel pin holes in the spacer section (J). Make sure grease passages are aligned.
11. Make sure the spacer section (J) is snug to the body. If the spacer section (J) is not square to the body, it is because the sleeves are slightly rotated out of position. Take a dead blow hammer (t2) and rap sharply on the high corner of the spacer section (J). This will rotate the spacer section (J) and sleeves into correct position.
- 73 -
ATTENTION
The tool holder must be level and square to the main body. Do not use an air wrench to thread the tie rods into the bottom nuts.
- 74 -
e. Turn each of the tie rods (Q) clockwise with a hand wrench (t6) until several threads are engaged. Turn each tie rod until it bottoms in the bottom nut (V) then back off tie rods two turns. Support tool holder (C).
13. Install the spring washers (AG). Apply a thin coat of grease (28) on the spring washers and install them with the gap at edge as shown below.
a. Pour specified amount of synthetic oil in past A sleeve. Any viscosity synthetic motor oil is acceptable.
OIL CAPACITY CAPACITY MODEL OUNCE (cc) GH06 1.5 (40) GH07 1.5 (40) GH1 1.75 (50) GH2/GHS2 3.5 (100) GH3 3.5 (100) GH4 3.5 (100) GH6 5 (150)
- 75 -
ATTENTION
Be careful pushing the gas head into position so as not to disturb the spring washers.
14. Install the gas head (L) and lock washers (U). a. Install the lock washers (U) onto tie rods (Q). b. Apply anti-seize compound on the lock washer faces and tie rod threads.
- 76 -
a. If a gap (d3) of about .19 - .25 inch (7 to 8 mm) is formed between the main body (A) and the gas head (L) when the top nuts (R) are tightened fully by hand, the setting may be regarded as normal. If the gap (d3) is larger than the mentioned dimension, this suggests that the spring washers have fallen out of position.
16.
Tighten all TOP NUTS with a TORQUE WRENCH to recommended torque specification shown in CHART 1, see page 105. (It may take several passes at each top nut to achieve this.) Check that no gap (d3) is noted between the sections.
- 77 -
a. Install the o-rings and the back up rings on the main body. b. Install the o-ring and the back up ring on the underside of the valve body. c. Apply a thin coat of grease (28) on the o-rings and the back up rings.
17.2
Fill hammer assembly (KK) with oil. Pour oil (t52) into the IN port (6) and the OUT port (5) of the hammer assembly. Let air that is trapped in the assembly purge out.
17.3 Install the valve body (W). a. Install the valve body (W) on the main body. b. De-grease the bolts and tapped holes in the main body. c. Apply adhesive on the bolts and tighten them to the specified torque, see page 106. 17.4 Install the bottom cap (Y). a. Apply a thin coat of grease on the o-ring (RR) and backup ring (SS) and install them on the bottom cap (Y). (Curl the back up ring to form a small circle before installing).
- 78 -
c. Tighten the bolts evenly to the specified torque, see page 106.
17.5 Install the valve spool (Z). Apply hydraulic oil or NPK assembly lube to the surface of the valve spool (Z). Then insert the valve spool (Z) from the top side into valve body (W). Make sure that the valve spool (Z) moves smoothly.
17.6 Install the plunger (BB) and the plunger bushing (AA). a. Apply a thin coat of grease on the o-rings (RR) and back up rings (SS) and install them on the plunger bushing (AA). (Curl the back up ring (SS) to form a small circle before installing.)
- 79 -
b. Apply grease to the surface of the plunger (BB). Insert grease into the plunger bore of the plunger bushing (AA). Then insert the plunger (BB) into the plunger bushing (AA).
c. Insert the plunger bushing in the valve body with the plunger operation pilot hole upward (8).
- 80 -
17.7 Install the swivel flange (EE). a. Apply grease (28) to the o-rings (RR) and the back up rings (SS), then install them on the swivel flange (EE). Install the swivel flange on the valve body. b. Tighten the bolts to the specified torque, see page 106.
c. Apply grease to the o-rings and the back up rings. Install them in the swivel elbow (DD). Install the seal rings (AI), the swivel elbow (DD), and stop ring (AH) on the swivel flange. d. Using snap ring pliers, install the snap ring (AJ) on the swivel flange (EE).
The JIC fitting on the swivel adapter is off set to clear the swivel flange bolts.
- 81 -
20. Grease the tie rods (GH6 ONLY). a. After the tie rods have been torqued, install grease fittings (30) as shown. Grease until no more grease is accepted. Remove the grease fittings and install the existing plugs (TT).
- 82 -
STANDARD TOOLS
DEMOLITION TOOL SHAPE APPLICATIONS Trenching Cutting casting gates Breaking oversize General demolition
CHISEL (FX)
The cross cut (FX) tool cuts at right angle, or crosswise, to the stick and boom of the excavator.
MOIL (P)
Concrete breaking Highway construction General demolition Secondary breaking Breaking oversize Slag removal
BLUNT (E)
OPTIONAL TOOL
ACCESSORY TOOLS
SPECIALTY TOOL SHAPE APPLICATIONS Edge of trenching Frost cutting
FROST CUTTER Cross cut (SX), In Line (SY) for GH07 thru GH4 ADAPTER TOOL for GH07 thru GH4 TAMPER PLATE (use with adapter tool) 9-1/2 x 9-1/2 for GH07 12 x 12 for GH1 thru GH2/GHS2 16 x 16 for GH3 thru GH4 POST and PIPE DRIVER (use with adapter tool) for GH1 thru GH4
ATTENTION
MAXIMUM CLEARANCE INCH (mm) 1/4 (6.5) 1/4 (6.5) 1/4 (6.5) 1/4 (6.5) 1/4 (6.5) 1/4 (6.5) 3/8 (10)
Step 2 Remove the tool from the tool holder. Measure the diameter (d16) of the bearing surface of the tool, which is located on each side of the retaining pin groove. The minimum tool diameter is compared to a new tool bushing only. If the tool is at or below the charted value, the tool must be replaced. NEW TOOL DIAMETER INCH (mm) 1.63 (41.4) 1.83 (46.6) 2.23 (56.6) 2.58 (65.6) 2.98 (75.6) 3.37 (85.6) 4.16 (105.6) MINIMUM TOOL DIAMETER INCH (mm) 1.43 (36.4) 1.63 (41.4) 2.02 (51.4) 2.38 (60.4) 2.81 (71.4) 3.2 (81.4) 3.8 (96.4)
- 84 -
MODEL
1.67 (42.4) 1.87 (47.4) 2.26 (57.4) 2.61 (66.4) 3.01 (76.4) 3.40 (86.4) 4.19 (106.4)
1.87 (47.4) 2.07 (52.6) 2.46 (62.6) 2.82 (71.6) 3.21 (81.6) 3.61 (91.6) 4.55 (115.6)
Compare the tool and bushings to the charts in Step 2 and Step 3. Choose the new component (tool or bushing) that will bring the maximum clearance to below the value seen in the chart of Step 1. Replacing both the tool and bushings would bring the clearance back to new.
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HAMMER MODEL
in GH06 GH07 GH1 GH2 GH3 GH4 GH6 1.26 1.46 1.77 2.05 2.36 2.68 3.31
mm 32 37 45 52 60 68 84
mm 37 42 50 57 65 73 89 0 0
in
mm 5 5 10 9 15 19 21
mm 47 52 62 73 82 91 111
- 86 -
TOOL INSPECTION
1. Deformation may occur on the tool in the retaining pin contact area (15) or thrust surface (31). If these areas are mushroomed, the tool may become difficult to remove from the tool holder. Dress with a grinder.
2. Excessive blank hammering will cause chipping (16) in the retaining pin contact area (15). If neglected, the chipping may reduce the life of the tool. Dress with a grinder.
3. If chipping (16) is found at the top of the tool, replace the tool. If neglected, the piston impact surface will be damaged (AM is normal, AL needs to be replaced).
- 87 -
d21 MODEL GH06 GH07 GH1 GH2/GHS2 GH3 GH4 GH6 INCH .25 .25 .38 .38 .38 .50 .50 MM 6.4 6.4 9.7 9.7 9.7 12.7 12.7
d16 (REF.) INCH MM 1.57 1.77 2.17 2.52 2.91 3.31 4.09 40 45 55 64 74 84 104
- 88 -
d23 = Length of tool from top to bottom. d22 = Length of tool exposed from bottom of tool bushing to end of tool. d16 = Diameter of bearing surface of tool. NEW TOOL DIAMETER (d16) INCH MM 1.63 41.4 1.83 46.6 2.23 56.6 2.58 65.6 2.98 75.6 3.37 85.6 4.16 105.6 NEW TOOL LENGTH (d23) INCH MM 19.3 490 20.7 527 23.6 599 25.5 648 28.5 725 33.0 838 38.0 966 NEW WORKING LENGTH (d22) INCH MM 12.2 311 13.1 333 13.6 346 14.4 367 16.1 408 18 458 19.7 500
NOTE: Minimum tool length is determined by the depth of material penetration that is required.
- 89 -
RETAINING PIN
Deformation may occur on the retaining pin in the tool contact area (AN). If this area is mushroomed, the retaining pin may become difficult to remove. Dress areas shown (AN) with a grinder.
- 90 -
LUBRICATION
CORRECT GREASE AND GREASE INTERVALS
Proper hammer maintenance requires a sufficient supply of the correct grease to the tool (chisel). The tool must be pressed against a hard surface until it stops up inside the hammer. This prevents grease from entering piston impact area and ensures proper distribution of grease between the tool and tool bushings. GREASE INTERVALS If the hammer is not connected to an Autolube system, see pages 93 and 94, the hammer must be greased at regular intervals to get the best life from the tool and tool bushings. There are two ways to determine grease intervals: First, grease the hammer at the beginning of the job until grease comes out between the tool and the lower tool bushing. Run the hammer until the shank of the tool starts to look dry. This determines the time interval for the greasing of this particular hammer on this particular job. Typically, this is 1 to 4 hours. Also, note the amount of grease needed to re-grease the tool. This gives you the amount of grease and how often it must be applied. An example would be that a particular hammer, on a particular job, requires half a tube of grease every 3 hours. This would be the greasing schedule you would set up. If this hammer was moved to another job, another grease schedule may have to be determined. Second, if you cant control the grease schedule, such as rental units, then have the operator grease the hammer once every hour of hammer operation. Again, grease the hammer until grease comes out between the tool and tool bushing. This is usually more often than required, but is far cheaper than replacing prematurely worn tools and tool bushings. CORRECT GREASE The type of grease used is very important. NPK recommends a lithium soap base EP (Extreme Pressure) NLGI #2 Grease, with Moly (Molybdenum Disulfide) or other surface protecting additives. A high drop point 500 F (260 C) grease is desirable. On the following page is a list of commonly available greases, by manufacturer and brand name that meet NPKs recommendations. NPK does not endorse any one brand as being superior to another. If you or your customers use a brand not listed, please call the NPK Service Department at 800-225-4379.
- 91 -
LUBRICATION
CORRECT GREASE FOR HYDRAULIC HAMMERS
MANUFACTURER Amalie Oil Co. Amoco
BRAND NAME LI-2M Rykotac EP Grease Amolith Grease 94601 Rykon Premium Grease EP (Grade 94108) Rykon Premium Moly Grease (Grade 94114) Amoco Molylith Grease 92006 GHD Bearing Gard-2
Amsoil, Inc. BP Oil, Inc. Caterpillar Cato Oil and Grease Company CITGO Conoco, Inc. Dryden Oil Company Exxon Fiske Brothers Refining Co. (Lubriplate) John Deere Kendall Mobil Muscle Products Corporation (MPC) NPK
Multipurpose Molydbenum Grease (MPGM) Moly Lithflex CX AS Citgo Extra Range Grease Super Lube M EP #2 Moly EP 2 Ronex Extra Duty Moly NLGI 2 MO-LITH No. 2 TY6333/TY6341 Moly High Temp L-424 Moly 372 PL-10 Powerlift Grease LP-10 Lithium EP Plus Universal Plus Lithium EP Grease Super Duty EP Grease (water resistant) Chisel Paste Adhezolith EP 2 Grease Philube MW Retinax AM Grease 71119 Retinax HD Grease Bearing Gard-2 Prestige Moly 2 EP Molytex EP 2 Unoba Moly HD #2 Unoba Moly HD #2
Pennzoil Phillips 66 Company Shell Standard Oil Company Sun Refining & Marketing Company Texaco, U.S.A. Union Oil Company Unocal
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LUBRICATION
CORRECT GREASE FOR HYDRAULIC HAMMERS NPK HAMMER GREASE
NPK now offers hammer grease specially formulated to meet severe job requirements. The grease is available in three different temperature ranges - 350, 500, and 2000. All are compatible with Autolube systems. Universal Plus and Super Duty are lithium soap based products that resists washout and contain NPK-10 additive for surface protection in friction affected areas. Chisel Paste is an aluminum complex soap base with 12% graphite and copper additives for extreme operating conditions. UNIVERSAL PLUS 350 deg 14 OZ. CARTRIDGE 120 LB. KEG 35 LB. PAIL 400 LB. DRUM SUPER DUTY 500 deg 14 OZ. CARTRIDGE 120 LB. KEG 35 LB. PAIL 400 LB. DRUM CHISEL PASTE 2000 deg 14 OZ. CARTRIDGE NPK PART NO. G000-1010 G000-1020 G000-1030 G000-1040 NPK PART NO. G000-1011 G000-1021 G000-1031 G000-1041 NPK PART NO. G000-1050
AUTOLUBE SYSTEMS
An automatic greasing system is recommended to reduce hammer tool and tool bushing wear. The NPK AUTOLUBE System is designed to automatically provide a continuous supply of grease to the hammer tool and tool bushing increasing tool and tool bushing life by reducing wear. The AUTOLUBE pump is capable of pumping EP2 grease in cold weather. The pump output is adjustable according to the requirements of the hammer model and to compensate for tool bushing wear.
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Upper and lower tool bushings can be cut out with carbon arc (t12) or oxygen and acetylene (t13). Start cutting in areas 1 and 2 (away from the bushing retaining pin bore (19) first, and then go to areas 3 and 4. Care should be given not to damage the bushing retaining pin bore (19).
Use either carbon arc (t12) or cutting torch (t13) to cut bushing (G).
Exercise care when cutting to avoid damaging the tool holder. If the tool holder bore is cut accidentally, grind the surface smooth to remove sharp edges and high spots.
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HYDRAULIC PRESS REQUIREMENT: 100 ton minimum All Models LIQUID NITROGEN METHOD
Clean the bore of the tool holder. The surface must have no sharp edges or high spots. Grind smooth, if necessary.
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1. Cut the bore oversize to Dimension d24. MODEL GH06 GH07 GH1 GH2/GHS2 GH3 GH4 GH6 DIMENSION d24 INCH MM 2.73 69.4 2.94 74.7 3.84 97.5 4.06 103.0 4.47 113.5 4.88 124.0 5.96 151.5
2. Weld the bore undersize to Dimension d26. Pre-heat the bore to 250F (120C). Use one of the following wires (or rod equivalent): Cronatron Cronalloy 7940 Eutectic 3010A Lincoln Lincore 33 Postal Postalloy 2892 SPL Stoody Built Up Or Equal MODEL GH06 GH07 GH1 GH2/GHS2 GH3 GH4 GH6 DIMENSION d26 INCH MM 2.36 60 2.56 3.43 3.70 4.09 4.49 5.55 65 87 94 104 114 141
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4. Dimension d27 is the diameter of the .25 (6 mm) undercut at the bottom of the bushing bore. MODEL GH06 GH07 GH1 GH2/GHS2 GH3 GH4 GH6 DIMENSION d27 INCH MM 2.65 67.2 2.64 67.0 2.84 72.2 2.84 72.0 3.59 91.2 3.58 91.0 3.98 101.1 3.97 100.9 4.38 111.2 4.37 111.0 4.77 121.2 4.76 121.0 5.87 149.2 5.87 149.0
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TOOL HOLDER
REPAIR OF EXTERIOR
When the hammer has been used for a long period of time, or operated with penetration of the tool holder into the material being broken, the exterior of the tool holder may become worn.
REBUILD PROCEDURE
1. Underlayment - Underlayment weld is necessary to build up the base material or over existing hardface weld. NOTE: You cannot hardface directly over old hardfacing. Welding Rod: Airco Austex 361, Cronatron 7770, Eutectic 3205, Postalloy 205, Stoody 2110 or equal. In Canada; NCH Canada, Inc. Hi-Pact #194 or equal. Dry welding rod at 300F +. Pre-heat the tool holder weld area to 150F and maintain this temperature during the welding operation. It is very important to maintain this temperature in cold environments. Adjust weld current to rod manufacturers specification. Peen each layer. Cool slowly. Cover weld in cold environments. 2. Hardface - Hardface can only be applied over base material or underlayment weld. Never hardface existing hardface. Welding Rod: Airco Tubecraft 1A, Cronatron 7355, Eutectic N6006, Postalloy 214, Stoody 31 or equal. In Canada; NCH Canada, Inc. Wear-X #176 or equal. Dry welding rod at 300F +. Pre-heat the tool holder weld area to 350F and maintain this temperature during the welding operation. It is very important to maintain this temperature in cold environments. Adjust weld current to rod manufacturers specification. Peen each layer. Do not exceed 2-3 layers of hardface. Cool slowly. Cover weld in cold environments.
19 RETAINING PIN BORE Leave sufficient clearance around the tool bushing retaining pin bore for removal or assembly. If necessary, a short length of 1 inch pipe can be welded in position over the hole to provide clearance. Grind flush after welding. VV REPAIR WELDMENT (see detail)
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PROCEDURE:
If a hammer with a failed tie rod is stopped immediately, only the failed tie rod must be replaced. If the hammer has been operated with a failed tie rod for more than one hour, all four tie rods should be magna-fluxed in the thread areas to check for stress cracks caused by the 3 remaining tie rods taking the extra load created when one tie rod breaks. The following procedure is for the replacement of a single tie rod. 1. Remove all snap rings and lock plates. 2. Remove the tie rod to be replaced. 3. Discharge the gas pressure. Refer to the DISCHARGING THE GAS PRESSURE section of the manual. 4. Loosen the three remaining tie rod top nuts until they are just hand tight. Do not loosen the top nuts (R) too far, as oil maybe lost from the gas head. 5. Apply Anti-Seize compound on the bottom threads of the new tie rod. Assemble into the hammer and thread into the bottom nuts.
6. Apply Anti-Seize compound to the top thread of the tie rod and on the washer faces. Place the washer over the top of the tie rod. 7. Hand tighten the top nut (R). 8. Tighten the top nuts. Refer to the TIE ROD TORQUE CHART section of the manual. 9. Install the lock plates. If a lock plate does not drop into place, tighten the top nut (R) until it does. 10. Install the snap rings. 11. Gas charge the hammer. Refer to the GAS CHARGING THE HAMMER section of the manual.
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NEW LENGTH d29 INCH MM 22.72 577 22.72 577 25.71 653 27.95 710 30.12 765 36.81 935 43.90 1115
MAXIMUM LENGTH d30 INCH MM 23.03 585 23.03 585 26.02 661 28.27 718 30.43 773 37.13 943 44.21 1123
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Chart 1 Socket Size Torque MODEL Ft/lbs (Nm) (in) (mm) GH06 150 (200) 1-1/16 27 GH07 150 (200) 1-1/16 27 GH1 185 (250) 1-1/4 32 GH2/GHS2 295 (400) 1-7/16 36 GH3 370 (500) 1-5/8 41 GH4 480 (650) 1-13/16 46 GH6 850 (1150) 2-1/2 63 *Sweeney 503 Anti-seize recommended. If you have any questions call the NPK Service Department at 800-225-4379.
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VALVE CASE BOLT TORQUE DIA ft/lb (Nm) M12 110 (150) M12 110 (150) M12 110 (150) M12 110 (150) M16 270 (365) M18 370 (500) M20 525 (710)
SWIVEL ADAPTER BOLT TORQUE DIA ft/lb (Nm) N/A N/A N/A N/A N/A N/A N/A N/A M8 30 (40) M8 30 (40) M12 110 (150)
*NOTE: TORQUES OF ALL BOLTS SHOWN ARE WITH THREADS BEING LUBRICATED.
HEX SOCKET SIZE BOLT DIAMETER M10 M12 M14 M16 M18 SOCKET HEAD CAP SCREW 8mm 10mm 12mm 14mm 14mm
HAMMER BRACKET MODEL BOLT TORQUE DIA ft/lb (Nm) GH06 1 500 (678) GH07 1 500 (678) GH1 1 500 (678) GH2/GHS2 1 500 (678) GH3 1-1/4 1000 (1356) GH4 1-1/2 1250 (1695) GH6 1-1/2 1250 (1695)
ADAPTER BRACKET BOLT TORQUE DIA ft/lb (Nm) 5/8 165 (225) 5/8 165 (225) 5/8 165 (225) 5/8 165 (225) 5/8 165 (225) 5/8 165 (225) 1 550 (745)
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MOUNTING PLATE
If the hammer has been overstressed due to improper operation or installed on too large a carrier, the mounting bracket may develop a fatigue crack. EXAMPLE OF REPAIRING A CRACKED PLATE 1. Drill 3/16 (5 mm) hole through the bracket at the end of the crack to prevent further crack propagation. 2. Grind out the crack and weld as shown. Use AWS E7016 or equivalent welding rod. 3a. For plate sizes up to 3/4 (20 mm) thick, use this weld joint:
3b. For plate sizes over 3/4 (20 mm) thick, use this weld joint:
4. Grind weld flush as shown. 22 is the direction of grinding, 23 is the direction of principal stress.
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WARRANTY STATEMENT
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If the NPK HYDRAULIC HAMMER is not to be used for a long period of time (months), it is recommended the nitrogen gas be discharged through the gas charge valve (M). The tool (HH) should be removed, and the piston (not shown) pushed all the way in. Be sure the hydraulic hoses (AO) are plugged, and grease the exposed end of the piston (N). Cover with a waterproof tarp (t21), not shown.
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FRACTIONS
32nds 64 s
th
DECIMALS
2 Place 3 Place
FRACTIONS
32nds 64 s
th
DECIMALS
2 Place 3 Place
.02 .03 .05 .06 .08 .09 .11 .12 .14 .16 .17 .19 .20 .22 .23 .25 .27 .28 .30 .31 .33 .34 .36 .38 .39 .41 .42 .44 .45 .47 .48 .50
.016 .031 .047 .062 .078 .094 .109 .125 .141 .156 .172 .188 .203 .219 .234 .250 .266 .281 .297 .312 .328 .344 .359 .375 .391 .406 .422 .438 .453 .469 .484 .500
.52 .53 .55 .56 .58 .59 .61 .62 .64 .66 .67 .69 .70 .72 .73 .75 .77 .78 .80 .81 .83 .84 .86 .88 .89 .91 .92 .94 .95 .97 .98 1.00
.516 .531 .547 .562 .578 .594 .609 .625 .641 .656 .672 .688 .703 .719 .734 .750 .766 .781 .797 .812 .828 .844 .859 .875 .891 .906 .922 .938 .953 .969 .984 1.000
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A. F.
HAMMER BODY IMPACT BUSHING/UPPER TOOL BUSHING G. LOWER TOOL BUSHING J. IMPACT RING/SPACER SECTION N. PISTON O. MAIN BODY A SLEEVE P. MAIN BODY B SLEEVE HH. TOOL
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MAIN BODY
GH06 GH3 REFERENCE: 1 TOOL END, 2 GAS END DIAMETER d5a d5b d5c
GH4 GH6
LENGTH d7
COMMENTS:
______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________
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COMMENTS:
______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________
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I.D. (d41)
I.D. (d41)
COMMENTS:
______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________
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LENGTH d13
COMMENTS:
______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________
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GH06 GH3
GH4 GH6
REFERENCE: 2 GAS END INSIDE DIAMETER d45 (GH06 GH3) d42 (GH4 GH6)
COMMENTS:
______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________
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REFERENCE: 1 TOOL END, 2 GAS END INSIDE DIAMETER d43 d44a d44b Dimensions to 0.000 inch (0.00 mm)
COMMENTS:
______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________
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CARRIER MANUFACTURER MODEL NUMBER SERIES SERIAL NUMBER DATE OF INSTALLATION _________________ DATE OF 20 HOUR INSPECTION ______________ WARRANTY REGISTRATION SENT
SERVICE RECORD
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www.npkce.com
H055-9640A.doc
03/09